目的 研究镍基高温合金在磨削加工过程中的亚表面损伤机理,利用分子动力学仿真分析手段,对比振动辅助磨削与常规磨削过程中镍基高温合金亚表面缺陷演化与亚表面缺陷原子数量变化,进而探究振动辅助磨削对镍基高温合金亚表面损伤的影响规律。方法 采用分子动力学方法建立振动辅助下立方氮化硼（CBN）单颗磨粒磨削镍基高温合金的磨削过程,通过仿真分析,研究微观尺度下镍基高温合金的亚表面损伤机理。借助仿真分析,研究振动辅助磨削下亚表面的形成机理。利用仿真与实验相结合的方法,对比振动磨削和常规磨削下镍基高温合金的磨削力、亚表面缺陷原子数量、类型及位错的变化情况,深入分析振动辅助磨削对镍基高温合金亚表面损伤的影响。结果 在磨具与工件接触后,工件原有的晶格结构发生变化,晶体内部产生亚表面缺陷,进而在工件内部形成亚表面损伤。在施加振动后,能够有效减小磨具的磨削力,且振动会抑制层错结构、位错缺陷和V型位错的产生,使工件内部的亚表面缺陷原子数量明显降低,从而减少镍基高温合金的亚表面损伤。结论 在磨削时,工件内部会产生V型位错,这是导致镍基高温合金亚表面损伤的重要原因。振动磨削通过抑制镍基高温合金内部V型位错的产生,从而降低镍基高温合金的亚表面损伤,获得更好的亚表面质量。
Abstract
To investigate the subsurface damage mechanism of nickel-based superalloys during the grinding process, the work aims to compare the changes in subsurface defects induced by vibration-assisted grinding and conventional grinding and further explore how vibration-assisted grinding affects the subsurface damage characteristics of nickel-based superalloys.
A single-grain grinding model of nickel-based superalloys using cubic boron nitride (CBN) tools under vibration assistance was established through molecular dynamics simulations. Based on simulation results, the microscopic subsurface damage mechanisms were analyzed. By integrating simulation with experimental data, variations in grinding forces, as well as the number, types, and dislocation behaviors of subsurface defect atoms under both vibration-assisted and conventional grinding conditions were compared. The effects of vibration assistance on subsurface damage formation were thoroughly examined.
Through the investigation of the subsurface damage mechanism in nickel-based superalloys under vibration-assisted grinding, it was observed that as abrasive grains continued to advance across the workpiece surface, the initial face-centered cubic (FCC) structure within the material progressively transformed into a hexagonal close-packed (HCP) structure during the grinding process. The HCP structure represented a form of crystallographic defect and was primarily composed of dislocation defects, vacancy defects, atomic clusters, and stacking faults. An increase in HCP content indicated a corresponding increase in subsurface defects within the workpiece. Furthermore, V-shaped dislocations were also generated during the grinding process, which were recognized as a significant contributing factor to subsurface damage in nickel-based superalloys.
A comparative analysis of grinding forces between conventional grinding and vibration-assisted grinding reveals that both tangential and normal forces are substantially reduced in the vibration-assisted process. The number of subsurface defects in nickel-based superalloys is significantly lower during vibration-assisted grinding compared to conventional grinding, indicating that vibration-assisted grinding effectively suppresses the formation of stacking faults and dislocation defects. Furthermore, the subsurface damage depth in nickel-based superalloys subject to vibration-assisted grinding markedly decreases relative to that observed in conventional grinding. By using dislocation extraction techniques to investigate dislocation evolution in nickel-based superalloys, it is found that vibration-assisted grinding inhibits the formation of V-shaped dislocations, thereby mitigating subsurface damage in these materials.
The microstructure of subsurface damage layers formed during vibration-assisted grinding and conventional grinding is analyzed with transmission electron microscopy (TEM). The results indicate that the subsurface damage depth in nickel-based single-crystal superalloys subject to conventional grinding is approximately 2.27 μm, whereas in vibration-assisted grinding, the damage depth is significantly reduced to approximately 39.5 nm. Experimental validation confirms that vibration-assisted grinding effectively reduces the extent of subsurface damage in nickel-based superalloys, aligning with both simulation and theoretical predictions.
The results demonstrate that upon contact between the grinding tool and the workpiece, the original lattice structure of the workpiece undergoes deformation, leading to subsurface defects within the crystal lattice and subsequently inducing subsurface damage. When vibration is applied to the grinding process, both the grinding force and the depth of subsurface damage are significantly reduced. Additionally, vibration effectively suppresses the formation of lamellar dislocations, dislocation clusters, and V-shaped dislocations, thereby decreasing the number of defect atoms in the subsurface region and minimizing the overall extent of subsurface damage in nickel-based superalloys.
关键词
振动辅助磨削 /
镍基高温合金 /
亚表面损伤 /
分子动力学 /
位错
Key words
vibration-assisted grinding /
nickel-based superalloys /
subsurface damage /
molecular dynamics /
dislocation
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